CN103596739A

CN103596739A - Method of treating a fiber cushion body

Info

Publication number: CN103596739A
Application number: CN201280027575.1A
Authority: CN
Inventors: 简·佩策尔
Original assignee: Schukra Geratebau GmbH
Current assignee: Schukra Geratebau GmbH
Priority date: 2011-06-10
Filing date: 2012-06-11
Publication date: 2014-02-19
Anticipated expiration: 2032-06-11
Also published as: US20140167328A1; WO2012167950A1; US9597846B2; CN103596739B; EP2532502A1; EP2532502B1

Abstract

A fiber cushion body (1), which is formed from cross-linked fiber material and which is resiliency deformable when load is applied along a main load direction (2), is treated using ultrasonic energy. A portion (21) of the fiber cushion body (1) is displaced, for example using a sonotrode (20), and ultrasonic vibrations are applied to the fiber cushion body (1) to re-shape the fiber cushion body (1) from a first shape to a second shape different from the first shape.

Description

Process the method for fiber cushion pad body

Technical field

The present invention relates to a kind of method of processing fiber cushion pad body.Especially, the present invention relates to a kind of method of post processing of the fiber cushion pad body that can be used for molding.

Background technology

Foam, for example polyurethane (PU) foam is widely used as for seat, for example, for the fabric liner of the interior material for vehicle of transport service.Foam is adhered to the back side of weaving face fabric.The composite of these foam-backs has the cushioning effect that the comfortableness of contact area or luxurious sense can be provided.

Use polyurethane foam as the padded coaming existent defect for seat.For example, the material of polyurethane foam backing can emission of volatile substances, and this causes vehicle or house inside " hazing ", and foam self can be oxidized in time, thereby causes material variable color.Recuperability is also the problem that must solve.

Due to these and other reason, still need another kind that the material with the similar buffering property of buffering property of foamed material can be provided with similar cost.The class material having received publicity is in this regard non-woven material, for example polyester nonwoven material.These materials can provide suitable backing to many fabrics, and solve some and utilize the insoluble demand of conventional PU foam cushion pad.

The manufacture that comprises air lay and " Struto " non-woven material technology vertically becomes the method for mat of the non-woven material of net and thermal, and the cushion pad with respect to previous non-woven material technology with economy and weight advantage is provided as far as possible.Many these technology are directed to the upright position in two-dimensional layer by short fiber.By connecting a plurality of these class preformed mats, can form fiber cushion pad body.

For the manufacture of another technology of three-dimensional fiber cushion pad body, comprise and loose fibrous material being inserted in three-dimensional mould and to being inserted into fiber heat supply in mould to cause heat cross-linking.At at least part of fiber before mould heat supply, be directed in mainly and aim at predetermined direction.This technology has following advantage: by using respectively suitable mould, can form multiple 3D shape.Yet, produce the needed working time of mould and can apply restriction to the quantity of obtainable different mould geometry with consequent cost, and therefore the quantity of the three-dimensional fiber cushion pad geometry that can manufacture is applied to restriction in moulding technology.

When using mould that fiber cushion pad body is formed to independent main body, can be incorporated in fiber cushion pad body rigidly fixing element.This retaining element can be used for that fiber cushion pad body is attached to structure member and maybe device is attached to fiber cushion pad body.Before being used for the thermal activation of binding fiber to mould heat supply, retaining element can be inserted in mould.Although retaining element can be incorporated in fiber cushion pad body reliably, use this independent retaining element can make removal process cost higher.

Summary of the invention

Consider above, this area still needs a kind of method that the fiber cushion pad body that solves some the demand is provided.Especially, this area needs a kind of making it possible in the situation that need to not realize for the particular manufacturing craft of each geometry the method that fiber cushion pad body is provided of diversified cushion pad body geometry.This area also needs a kind of method that makes removal process more easily to implement when retaining element is provided.

These and other demand is by the method for the processing fiber cushion pad body as independent claims limited and solve by corresponding fiber cushion pad body.Dependent claims limits embodiment.

According to embodiment, in the rear procedure of processing after forming fiber cushion pad body, to fiber cushion pad body, apply ultrasonic energy, to change the geometry of fiber cushion pad body.This can carry out according to the needs of the concrete purposes of fiber cushion pad body the change of geometry, and does not need to provide the particular manufacturing craft of all geometric characteristic of end product.In addition, with ultrasonic energy, change the geometry of fiber cushion pad body, also can produce the constricted zone of the density with increase.This region can be used as the retaining element of the integration that formed by the identical fibrous material of the body with cushion pad body.This provides the advantage about recuperability.

According to an aspect, provide a kind of method of processing fiber cushion pad body.By the fibrous material being cross-linked, form fiber cushion pad body.Fibrous material is heat-activatable at least partly.Before processing, fiber cushion pad body has the first shape.Movable part fiber cushion pad body, and apply ultrasonic vibration to fiber cushion pad body, so that fiber cushion pad body is reinvented into and first variform the second shape from the first shape.

In the method, use ultrasonic technology to carry out rear processing to fiber cushion pad body.Thus, can after molding fiber cushion pad body, to fiber cushion pad body, carry out the change of geometry.This makes can realize various 3D shapes from had the fiber cushion pad body of identical the first shape before post processing.Can use ultrasonic bonding operation to realize complicated geometry in accurate mode.

When applying load along main load direction, fiber cushion pad body is elastically deformable.As used herein, term " the first shape " and " the second shape " refer to respectively in wherein load not being applied to the shape of the fiber cushion pad body of the state that ceases on fiber cushion pad body.

Fiber cushion pad body can be Unitarily molded fiber cushion pad body.This Unitarily molded fiber cushion pad body can form to cause the thermal activation of binding fiber by fibrous material being inserted in mould and to its heat supply.Gained fiber cushion pad body is not for needing independent fiber cushion mat whole said three-dimensional body connected to one another.By using ultrasonic energy to process this Unitarily molded fiber cushion pad body, can further strengthen structural stability.Apply in mould, by loose fibrous material, formed hot in the situation that but not by after the Unitarily molded fiber cushion pad body that forms of the individual course of vertical shape fiber connected to one another there is no sharp-pointed zone boundary.This sharp-pointed zone boundary can be potential mechanical disruption line.The Unitarily molded fiber cushion pad body that uses ultrasonic energy to carry out rear processing alleviates splintering problem.

Fiber cushion pad body can be to present that fibre density and/or directional flattening change but not at the whole fiber cushion pad body of the sharply transition at place, zone boundary.At least, after processing, fiber cushion pad body can be included in the different region of density and/or fiber alignment aspect.Density and/or fiber alignment change smoothly in the transitional region being disposed between the region with different densities and/or fiber alignment.

Use described method, use the supersonic generator of suitable shape can in fiber cushion pad body, produce one or more trim slots.Can be connected on and in trim slots, trim materials are welded direct to fiber cushion pad body by supersonic welding.

Use described method, can produce the fixing point of the element to fiber cushion pad body to be attached.

Can apply ultrasonic vibration to fiber cushion pad body part.In order to illustrate, the part of removable fiber cushion pad body to be to form recess in fiber cushion pad body, and can to fiber cushion pad body part, apply ultrasonic vibration to cause the thermal activation of the heat-activatable fibrous material in recess area.Thus, recess can form and hold the parts different from fiber cushion pad body.

Can move described part with the supersonic generator that also applies ultrasonic vibration for part.

Can in fiber cushion pad body, produce constricted zone, there is the region of the density of increase.When fiber cushion pad body has the first shape, fiber cushion pad body can have the first density at described part place.Can carry out moving and applying of ultrasonic vibration, so that fiber cushion pad body has the second density at the face place of recess after applying ultrasonic vibration, the second density is greater than the first density.Thus, form the FX being made by the identical material of the body with fiber cushion pad body.FX has the rigidity of increase for parts are attached with it, but does not need the different material of the bulk material from fiber cushion pad body to fire in fiber cushion pad body.The FX being formed by the fibrous material compressing can fixing connector, and for example screwed plug or tree connector maybe can be by providing the fibre structure intensity of increase to work in another way.

Described method can comprise flexible material, particularly flexible weaving material are attached to the face of recess.Flexible material can be trim materials.Thus, the face of recess can be used as the fixing point of trim materials.

Flexible material can be heat-activatable.Flexible material can be the trim materials from polyester fiber.Can apply ultrasonic vibration to flexible material and fiber cushion pad body, flexible material is attached to fiber cushion pad body by ultrasonic bonding.Thus, can reduce the needed component count of attached flexible material.Can be by ultrasonic bonding line concealing can be by applying in the formed trim slots of ultrasonic vibration to fiber cushion pad body.

Described method can comprise the face that rigid element is attached to recess.Thus, the face of recess can be used as the fixing point of rigid body.Rigid body can be the assembly of environmental system, for example, for heating or heating or the cooling system of cooling seat.Rigid body can be the assembly of seat adjustment system, for example power actuator.

Can make the face of connector and recess directly adaptive rigid element is attached to the face of recess.Because described mask has the density of increase, needn't provide the independent retaining element being molded onto in fiber cushion pad body to come with connector adaptive.

Recess can form has the section launching along the direction from fiber cushion pad body surface towards fiber cushion pad body inside.

Fiber cushion pad body can have main load direction.In at least one region of fiber cushion pad body, fiber can be mainly directed along main load direction.In described region, more than 50% fiber can have the orientation that becomes to be less than the angle of 45 ° with main load direction.Thus, can obtain good elastic characteristic.

Fiber cushion pad body can have the interarea extending perpendicular to main load direction.The section that can comprise interarea through mobile part.The described section of interarea can move to produce recess along the direction parallel with main load direction.Thus, recess can be formed at fiber cushion pad body for example on the face corresponding with the B face of automobile seat.This face is particularly suitable for holding larger assembly.

Fiber cushion pad body can have the inferior face extending in parallel with main load direction.The section that can comprise time face through mobile part.The described section of inferior face can move to produce recess along the direction perpendicular to main load direction.Thus, recess can be formed at the position that is suitable for contained structure element.

Can to fiber cushion pad body, apply ultrasonic vibration by supersonic generator, by supersonic generator, move described part simultaneously.The region that thus, can produce the density increasing at side and the place, bottom surface of recess.In the movement of whole described part, can apply continuously ultrasonic vibration.Can before starting movement or when starting to move, start to apply ultrasonic vibration.

Can after described part is mobile, start to apply ultrasonic vibration to fiber cushion pad body.Thus, can produce the region of the density with increase to occupy less surface area, and/or can regulate the characteristic of the sidewall of recess.

Treated fiber cushion pad body can be used for seat.Treated fiber cushion pad body can be used for automobile seat, aero seat, train chair or public transportation seat.Treated fiber cushion pad body can be used for the seat of taking one's seat or handling official business and taking one's seat for family.Described method can comprise treated fiber cushion pad body is installed in this seat.

According to another embodiment, provide a kind of method of manufacturing fiber cushion pad body.In described method, to mould, supply with the loose fibrous material that comprises heat-activatable binding fiber.To being filled into fiber heat supply in mould with thermal activation binding fiber, form the fiber cushion pad body of molding.Use the fiber cushion pad body of the disposal methods molding of either side or embodiment.

In described method, molding fiber cushion pad body.This makes the fiber cushion pad body can be with the form manufacture of whole main body, and does not need to treat the independent mat of vertical shape fiber connected to one another.Term " loose fibrous material " refers to the fibrous material that is not non-woven material or weaving material form of fabric as used herein.Loose fibrous material also can comprise the aggregation of fiber, for example fibre bundle.

Fibrous material can comprise fiberfill fibers and binding fiber.Fiberfill fibers can have the linear quality density between 10 dtexs and 100 dtexs.Binding fiber can have the linear quality density between 7 dtexs and 40 dtexs.Fiberfill fibers can have at least length of 80mm.Or fiberfill fibers length may be selected to be at 12mm in the scope of 70mm.

Fiber can be directed before heat supply.Thus, can form fiber cushion pad body, wherein, at least one region of described fiber cushion pad body, fiber has the privileged direction corresponding with the main load direction of described fiber cushion pad body.Can obtain the flexible touch of hope of fiber cushion pad body and good gas permeability.

Mould can have two interareas at the opposite side of recess, and described recess is defined in therebetween, and described interarea can relative to each other move.By the interarea of mould is relative to each other moved, can change at the interarea place of mould orientation and the density of fibrous material.Thus, the fiber cushion pad body of molding can form has density and/or the fiber alignment surf zone different from Hookean region, and in described Hookean region, fiber has the preferential fiber alignment corresponding with main load direction.Make the interarea of mould relative to each other move and also contribute to the fiber in directed mould recess area, in described region, wish that fiber is directed along the privileged direction corresponding with main load direction, to form the Hookean region of fiber cushion pad body.

The loose fibrous material being supplied in mould can be along the direction compression parallel with main load direction before heat supply.Thus, density and/or the fiber alignment region different from Hookean region can be formed on the interarea of fiber cushion pad body.The main load direction of formed fiber cushion pad body conventionally can be vertical along the interarea with fiber cushion pad body direction extend.In embodiments, the fibrous material being inserted in mould can be along two direction compressions that are perpendicular to one another before heat supply.

Alternately or additionally, the loose fibrous material being supplied in mould can be along the direction compression vertical with main load direction before heat supply.Thus, the region that density is different from Hookean region can be formed on the side of fiber cushion pad body.

The replacement scheme of Local Contraction fibrous material or other scheme before the thermal activation of binding fiber, can be at Local Contraction fibrous material after the thermal activation of binding fiber or the fiber cushion pad body being formed by it.By after the thermal activation of binding fiber, the part of Local Contraction fiber cushion pad body in the cooling procedure of fiber cushion pad body for example, can reduce the potential deviation of the net shape of fiber cushion pad body shape and hope.

According to embodiment, fiber can be directed afterwards in being inserted into mould.Fiber can be used air-flow, particularly air stream directed.

Can be in air-flow to the fibrous material of mould feeding loose.Can control the flow pattern of air-flow and carry out orientation with the fiber in mould.Fill level that can be based on fibrous material in mould is controlled the flow pattern of air-flow.For this reason, mould can have the opening that runs through for air-flow.

After in being inserted into mould, fibrous material is carried out to orientation, can regulate position and/or the size from one or more region of mould extracting gases based on fill level.Can be from mould extracting gases on the interarea of mould, the interarea of described mould is spaced apart along the direction corresponding with main load direction.Can be in the location of the interarea of mould from mould extracting gases, described region arranges respectively lower than the current fill level of fibrous material in mould.

Fiber is directed before can be in being inserted into mould.Loose fiber can be deposited on conveyer, and directed in can be on being deposited on conveyer.Can use air-flow, for example air stream is realized fiber is carried out to orientation.Can use for produce other technology that network fiber is arranged that is parallel-laid on conveyer.Then directed fiber can be transferred in mould from conveyer, so that fiber alignment is directed along the corresponding direction of the main load direction with gained fiber cushion pad body.

Before can be in being inserted into mould, fiber be preheating to the temperature lower than the heat activation temperature of binding fiber.Thus, can be reduced in the amount that fiber is inserted into the heat energy that must supply with to fiber after mould.

The air-flow that can use warm gas, air or steam is to the fiber heat supply in mould.

Fibrous material can comprise binding fiber and fiberfill fibers.Binding fiber can be two component (BiCo) fibers.In order to illustrate, binding fiber can have core and coating.Core can be formed by polyester or polyamide.Coating can be formed by the polyester of polyamide or modification.Binding fiber can have trilobal cross section.For example, fiberfill fibers can be formed by polyamide or polyester.Fiberfill fibers has the melt temperature higher than the heat activation temperature of binding fiber.Fiberfill fibers can be straight, spiral, tool ripple etc., and can be used for the volume of fiberfill fibers cushion pad body.

Can control in the mode of spatial variations the performance of fiber cushion pad body, the particularly rigidity of fiber cushion pad body, elasticity or damping behavior.This can regulate by the mode with spatial variations composition, density or the fiber alignment of fibrous material to realize.

Can before the fiber cushion pad body that uses ultrasonic energy processing molding, from mould, remove the fiber cushion pad body of described molding.

According to another aspect, provide the fiber cushion pad body of the method manufacture that utilizes an aspect or an embodiment.

According to another aspect, provide the seat of the fiber cushion pad body that comprises the method manufacture that utilizes an aspect or an embodiment.

Embodiment of the present invention are described with reference to the accompanying drawings.

Accompanying drawing explanation

Fig. 1 is the schematic cross section of fiber cushion pad body.

Fig. 2 to 4 is presented at the fiber cushion pad body of the Fig. 1 in each stage of the method for processing fiber cushion pad body.

Fig. 5 is the schematic cross section of treated fiber cushion pad body.

Fig. 6 is the schematic cross section of another treated fiber cushion pad body.

Fig. 7 and 8 is illustrated in the recess forming in treated fiber cushion pad body.

Fig. 9 is for being illustrated in the schematic diagram of the method molding fiber cushion pad body of manufacturing fiber cushion pad body.

Now with reference to accompanying drawing, exemplary embodiment of the present invention is described.Although some embodiments will be described under the background in concrete application, described embodiment is not limited to this application.In addition, unless expressly stated otherwise,, otherwise the feature of each embodiment can combination with one another.

Method with reference to Fig. 1 to 4 interpretation process fiber cushion pad bodies.Fig. 1 is the schematic cross section of fiber cushion pad body 1 before processing fiber cushion pad body 1.Cross-sectional view of fiber cushion pad body 1 during Fig. 2 to 4 is presented at processing method or after it.Cross-sectional view is respectively along the planar interception vertical and parallel with the main load direction 2 of fiber cushion pad body 1 with the interarea of fiber cushion pad body 1.

With reference to Fig. 1, pending fiber cushion pad body 1 is configurable as seat cushion.Fiber cushion pad body is configured to provide elastic characteristic when the power of pointing to along main load direction 2 is applied on fiber cushion pad body 1.

Fiber cushion pad body 1 has two

interareas

3,4, and it is arranged as on fiber cushion pad body 1 opposite each other.Interarea 3,4 can have the shape of almost plane, is substantially perpendicular to main load direction 2 and extends.Fiber cushion pad body 1 can be configured to the normal that makes winner's load direction 2 limit the plane of

interarea

3 and 4.

Fiber cushion pad body 1 can be the independent main body being formed by heat cross-linking fabric integer.The fibrous material that forms fiber cushion pad body can comprise at least two kinds of dissimilar fibers, i.e. binding fiber and fiberfill fibers.Binding fiber is can be by carrying out the fiber of thermal activation to its heat supply.After thermal activation, at least a portion melting of each binding fiber, thus cause forming fiber matrix.Various known fiber types can be used as combination and fiberfill fibers.The fibrous material that forms fiber cushion pad body can comprise the fiber that can be obtained and/or can be reclaimed with efficient way by salvage material.Binding fiber can be two component (BiCo) fibers.Binding fiber can have the heat activation temperature lower than the melt temperature of fiberfill fibers.According to exemplary embodiment, binding fiber can be to have the core of polyester or polyamide and have polyamide or the BiCo fiber of the coating of modified poly ester.BiCo fiber can have trilobal cross section.Fiberfill fibers can be formed by polyester or polyamide, and has at least the melt temperature higher than the melt temperature of the coating of binding fiber.Fiberfill fibers can have the linear quality density between 10 dtexs and 100 dtexs.Binding fiber can have the linear quality density between 7 dtexs and 40 dtexs.The fibrous material that forms fiber cushion pad body can comprise the fiberfill fibers of more than one types and/or the binding fiber of more than one types.

Can form pending fiber cushion pad body by any other suitable technology.In order to illustrate, can make to carry out processing hereinafter described by connecting the fiber cushion pad body of the mat formation of vertical one-tenth network fiber.

Fiber cushion pad body 1 comprises a plurality of different regions 5 to 7.Described region is differing from one another aspect the feature fiber alignment of fiber cushion pad body 1 and/or density.Between zones of different, there is no sharp borders.Fiber cushion pad body 1 but present fiber alignment or the gradually transition of fiber cushion pad body density between different piece.

Fiber cushion pad body 1 has Hookean region 5.Hookean region 5 has the fiber alignment corresponding with the main load direction 2 of fiber cushion pad body.The privileged direction that is the fiber in Hookean region is corresponding with main load direction 2, and vertical with at least one interarea 3 of fiber cushion pad body 1.Due to the statistical distribution of formation, fiber shape and the fiber alignment of fiber matrix, not all fibres fiber all can point to along the main load direction 2 in elastic part.If more than 50% fiber is respectively to be less than the angle orientation of 45 ° with respect to main load direction 2, Hookean region 5 can be considered the fiber alignment having along main load direction 2.In other words, in Hookean region 5, most of fiber is the angle setting that is greater than 45 ° with the plane with respect to interarea 3.

Fiber configuration in elastic part 5 is schematically shown in illustration 15.As seen in fig. 15 in inserted, most of fiber in Hookean region 5 can be to be less than the angle orientation of 45 ° with respect to main load direction, and fibrous septum can be enough large, so that fiber can turn to when the load of pointing to along main load direction 2 is applied on fiber cushion pad body.Make the main interconnective cross filament of fiber be arrangeding in parallel with main load direction 2 make it possible to form fiber matrix in Hookean region 5.

Fiber cushion pad body 1 also comprises other region 6,7 that is arranged at respectively interarea 3 and 4 places.Other region 6 and 7 is different from Hookean region 5 aspect at least one in fiber alignment or fiber cushion pad body density respectively.In the fiber cushion pad body 1 of Fig. 1, the fiber in other region 6 and 7 has respectively and the parallel plane privileged direction that its interarea is set.Fiber cushion pad body can be greater than the density in Hookean region 5 in the density at

interarea

3 or 4 places.Or the density of this increase also can produce in the processing of using ultrasonic energy.

The fiber configuration being arranged in other region 6 at interarea 3 places is schematically shown in illustration 16 places.As seen in fig. 16 in inserted, the most of fiber in region 6 can be less than with respect to the plane of interarea 3 the angle orientation of 45 °, and fiber can have the bulk density that is greater than elastic part 5.Be arranged at other region 7 on another interarea 4 and can there is aspect fiber alignment and fiber cushion pad body density the configuration similar to configuration in region 6.

Fiber cushion pad body 1 can form in independent mode, and fiber alignment and density can be respectively at Hookean region 5 and other region 6 and 7(respectively) between transition gradually.Fiber cushion pad body 1 comprises the transitional region 8 between other region 6 being arranged on Hookean region 5 and interarea 3.In transitional region 8, fiber alignment tapers to the fiber alignment in other region 6 interarea 3 from the fiber alignment of Hookean region 5, and the density of cushion pad body tapers to the density in other region 6 interarea 3 from the density of Hookean region.

Fiber cushion pad body 1 comprises the transitional region 9 between other region 7 being arranged on Hookean region 5 and interarea 4.In transitional region 9, fiber alignment tapers to the fiber alignment in other region 7 interarea 4 from the fiber alignment of Hookean region 5, and the density of cushion pad body tapers to the density in other district 7 interarea 4 from the density of Hookean region 5.

The fiber cushion pad body 1 that forms thus independent said three-dimensional body has the height 12 that can be greater than 4cm.Hookean region 5 has height 11, and is set to

interarea

3 and 4 spaced apart.

In fiber cushion pad body 1, have along the Hookean region 5 of the fiber alignment of main load direction 2 good ventilation and elasticity is provided.In the situation that form fiber cushion pad body 1 in independent mode by heat cross-linking fiber, obtain good durability and comfortableness.The processing of the use ultrasonic vibration by next describing is retained with reference to Fig. 1 described these the various features of fiber cushion pad body.

In order to change the geometry of fiber cushion pad body 1, the part 21 of mobile fiber cushion pad body 1, and to fiber cushion pad body 1 part, apply ultrasonic vibration in this region.Thus, realize the thermal activation of binding fiber, cause crosslinked.When fiber cushion pad body 1 is again cooling, the shape through changing of anchoring fiber cushion pad body.The first shape of fiber cushion pad body when thus, fiber cushion pad body does not apply load to fiber cushion pad body before can comfortable processing is reinvented the second shape when not applying load to fiber cushion pad body after processing.

Fig. 2 shows when the fiber cushion pad body 1 when moving the part 21 of the plane that is arranged at first interarea 3.By supersonic generator 20, part 21 is moved.The supersonic generator 20 being only illustrated schematically in Fig. 2 can have any suitable geometry.The geometry of supersonic generator 20 can be selected by the alteration of form based on carrying out fiber cushion pad body 1.In order to illustrate, if form, be recessed to the trim slots in fiber cushion pad body, can use the supersonic generator with narrower cross-sectional area to be inserted in fiber cushion pad body 1 contributing to.If form recess on the larger region of fiber cushion pad body, can use the supersonic generator with comparatively large cross-sectional area.

Supersonic generator 20 vibration, and ultrasonic vibration is applied in the part on the fiber cushion pad body 1 of its adjacency.The local ultrasonic energy thermal activation binding fiber of supplying with, thus contribute to fiber cushion pad body 1 to be deformed into the second shape from the first shape shown in Fig. 1.After supersonic generator 20 is quit work during cooling fibrous material, fixing cross-linked structure.The shape through changing of anchoring fiber cushion pad body thus.

Supersonic generator 20 can apply ultrasonic vibration continuously to fiber cushion pad body 1, is depressed in fiber cushion pad body 1 simultaneously.Or the activation of supersonic generator 20 can be delayed, until after part 21 is mobile.Time according to activating supersonic generator 20, can produce the recess with different qualities.

By making the part 21 of fiber cushion pad body 1 move Local Contraction fibrous material towards the inside of fiber cushion pad body 1.By supplying with ultrasonic energy in conjunction with supersonic generator 20 is further depressed in fiber cushion pad body 1, the cross filament network that partial melting is initial, and in fiber cushion pad body, the face place of formed recess forms the region of the density with increase, when stopping applying ultrasonic energy, by cross filament, fixes described region.

Fig. 3 shows the fiber cushion pad body when fiber cushion pad body has the second shape.

By movable part 21 and apply ultrasonic vibration, first shape 10 of the shape of fiber cushion pad body 1 before processing as shown in fig. 1 changes over the second shape 30.The part of fiber cushion pad body moved and part apply after ultrasonic vibration, in the face of fiber cushion pad body 1, form recess 23.

Because this is processed, in fiber cushion pad body 1, adjoin the region 24 that recess place forms the fibre density with increase.Dotted line schematically shows the characteristic area of the large at least given factor of bulk density in the density ratio Hookean region 5 of fiber cushion pad body wherein.For the fiber cushion pad body that is whole main body by fibrous material molding, density and/or fiber alignment vary continuously to Hookean region 5 from the region 24 with the density of increase.

Illustration 26 illustrates fiber alignment and the density at 25 places, bottom surface of recess 25.The density of the fiber cushion pad body at face 25 places is greater than the density of fiber cushion pad body in the Hookean region 9 shown in 15.The density of the fiber cushion pad body at face 25 places is also greater than the density at part 21 places before processing fiber cushion pad body 1, as indicated in the illustration 16 in Fig. 1.

By using ultrasonic vibration to process fiber cushion pad body, optionally compress the region of cushion pad body.The thermal activation of binding fiber causes heat interconnection, when fiber cushion pad body 1 can be cooling described in the region of the fixing density increasing of heat interconnection.

Fig. 4 shows the fiber cushion pad body when having the region 24 of the density of increase and be used as retaining element.Parts 27 are contained in recess 23.Directly adaptive for the connector 29 of parts 27 and the region of fiber cushion pad body 24.Thereby the retaining element for parts 27 is served as in region 24.Region 24 is incorporated in fiber cushion pad body 1, and is formed by the fibrous material identical with other region of fiber cushion pad body 1.Do not need the retaining element that the different material of the fibrous material by from fiber cushion pad body 1 is formed, for example metal retaining element is incorporated in fiber cushion pad body.

Parts 27 can be rigid elements.Parts 27 can be for heating and/or the cooling wherein assembly of the environmental system of the seat of fiber cushion pad body 1 to be installed.Parts 27 can be actuator assemblies, and the assembly of power actuator for example, for regulating the wherein assembly of the seat of fiber cushion pad body 1 to be installed.

Can carry out other change to the geometry of fiber cushion pad body 1.The alteration of form of hope that can be based on fiber cushion pad body 1 is selected the shape of supersonic generator 20.In order to illustrate, if form and compare with its length the groove that width is less, can use the suitable supersonic generator of width of width and groove in fiber cushion pad body.

The parts that are different from rigid element 27 also can be attached to the region 24 of the density with increase.In order to illustrate, can use the attached trim materials in region 24 of compressed fibrous material.In this case, recess 24 can form the trim slots of extending along one or several side of fiber cushion pad body 1, so that trim materials can be attached to fiber cushion pad body.The position that trim materials are attached to fiber cushion pad body can be recessed in trim slots, described trim slots forms by pushing fibrous material along inward direction with supersonic generator when applying ultrasonic vibration, thereby forms the recess of the face with at least one the fibrous material density with increase.

If trim materials are formed by thermoplastic fibre or comprise thermoplastic fibre, trim materials can be used ultrasonic bonding to be attached to fiber cushion pad body.Sealing wire can be arranged in as in the trim slots with reference to Fig. 2 and 3 formation of describing.Can to form therein trim slots, abreast trim materials be ultrasonically bonded to fiber cushion pad body 1 with making the distortion of fiber cushion pad body.Can apply ultrasonic vibration by supersonic generator, with the thermal activation of binding fiber that causes fiber cushion pad body, for fixedly thering is the region 24 of the density of increase, and trim materials and fiber cushion pad body 1 be merged.

Can use and according to the processing method of an embodiment, in fiber cushion pad body, form diversified recess.This makes it possible in the rear process operation of fiber cushion pad body 1, produce diversified fiber cushion pad geometry, and need to be for each the particular manufacturing craft in these geometries.

Fig. 5 demonstration has been used supersonic generator ultrasonic vibration to be applied to the cross-sectional view that carries out another fiber cushion pad body 31 of rear processing on fiber cushion pad body.The interarea 32 of fiber cushion pad body 31 comprises a plurality of recesses 33 to 35.Recess 33 to 35 can form has difformity.Each in recess 33 to 35 can be by supersonic generator is pressed onto in fiber cushion pad body and is formed, along with supersonic generator is applied to ultrasonic vibration part on fiber cushion pad body 31.Recess 33 to 35 can from face 32 wherein substantially the first shape of level and smooth fiber cushion pad body start to form.

Recess 33 can have rectangular shape.Wherein compressed fibrous material is to provide the region 38 of high stiffness to be formed at the face place of recess 33.Can make connector 41, for example screwed plug and region 38 screw threads are adaptive.The region of the density that this class at the place, side of recess 33 increases can be depressed into supersonic generator in fiber cushion pad body and form simultaneously by supplying with ultrasonic energy to fiber cushion pad body.

Another recess 34 can have triangular cross section.Can form recess 34 with the supersonic generator with corresponding triangular cross section.Wherein compressed fibrous material is to provide the region 39 of high stiffness to be formed at the face place of recess 34.Can make connector 42, for example external diameter is greater than tree connector and region 39 adaptations of the internal diameter of recess 34.

Connector 41,42 can have any in various functions, for example, fiber cushion pad body 31 is connected to structural detail or cladding material is fastened to fiber cushion pad body 31.

Another recess 35 can form trim slots.Recess 35 can have the first 36 of the face 32 that extends to fiber cushion pad body 31 and the second portion 37 arranging further from face 32.In the plane of the longitudinal axis perpendicular to trim slots, second portion 37Bi first 36 is wide.Be that trim slots comprises the section launching along the direction of the inside towards fiber cushion pad body 31 from face 32.Wherein compressed fibrous material is to provide the region 40 of high stiffness to be formed at the lower side place of recess 35.Trim materials 43 are attached to the fiber cushion pad body 31 in recess 35.Trim materials 43 can come attached with the suitable attachment structure being arranged in recess 35.In order illustrating, can to use line 44 and line 44 be adhered to the connector 45 of the bottom surface of recess 35.

Recess 35Zi first 36 launches along the direction of the inside towards fiber cushion pad body to the transition position of second portion 37.This recess arrangement can be by cutting fiber cushion pad body the fibrous material of surface to form first 36, then with supersonic generator, form second portion 47 and realize.First 36 also can form with supersonic generator.

Fig. 6 demonstration has been used supersonic generator ultrasonic vibration to be applied to the cross-sectional view that carries out another fiber cushion pad body 51 of rear processing on fiber cushion pad body.The interarea 52 of fiber cushion pad body 51 comprises a plurality of recesses 53 and 54.

Recess

53,54 can form has difformity.Each in

recess

53,54 can be by supersonic generator is pressed onto in fiber cushion pad body and is formed, along with supersonic generator is applied to ultrasonic vibration part on fiber cushion pad body 51.

Recess

53,54 can from face 52 wherein substantially the first shape of level and smooth fiber cushion pad body start to form.

Recess 53 can have rectangular shape.Wherein compressed fibrous material is to provide the region 57 of high stiffness to be formed at the face place of recess 53.Rigid element 61 is contained in recess 53.Rigid element is used with the direct adaptive connector 62 in region 57 with the density of increase and is adhered to fiber cushion pad body 51.Rigid element 61 can be that environmental system is for example for heating and/or the assembly of cooling environmental system or for activating the assembly of actuator assemblies of the assembly of the seat that fiber cushion pad body 51 is wherein installed.

Another recess 54 can form trim slots.The second portion 56 that recess 54 can have first 55 and launch along the direction of the inside towards fiber cushion pad body 51 from face 32.Recess 54 can be explained to form as the recess 35 with reference to Fig. 5.The direct adaptation in district 58 of the fibrous material of the compression that finishing covering 43 forms by connector 63 and lower side place in recess 54 is attached to fiber cushion pad body 52.

The impact that the shape in the region of the recess forming in fiber cushion pad body and the fibrous material of compression and characteristic are activated by the suitable timing of supersonic generator can.In order to illustrate, can be according to whether just activating supersonic generator to apply ultrasonic vibration when supersonic generator is pressed to fiber cushion pad body, or no only at it after movable part fibrous material, activate supersonic generator to apply ultrasonic vibration after in being depressed into fiber cushion pad body, obtain the different surfaces profile of the outer shape of fiber cushion pad body.Similarly, can be according to the time that supersonic generator activates and supersonic generator moves, the different spaces that is attained at the constricted zone of recess place formation distributes.

Fig. 7 illustrate under not applying ultrasonic vibration situation, first supersonic generator is depressed in the ban in fiber cushion pad body and after the cross-sectional view of the time fiber cushion pad body that can form while activating.Suppose that described supersonic generator has rectangular shape, the side 65 of the recess 64 forming in the surface of fiber cushion pad body tilts more slowly, and non-perpendicular to the face orientation that wherein forms the fiber cushion pad body of recess 64.The region 66 of the fibrous material of compression concentrates near the bottom surface of recess 64.

The cross-sectional view of the fiber cushion pad body that Fig. 8 can form when illustrating when in supersonic generator is depressed into fiber cushion pad body time its activation and applying ultrasonic vibration.Suppose that supersonic generator has rectangular shape, the side 68 of the recess 67 forming in the surface of fiber cushion pad body is directed with the substantially parallel ground of direction supersonic generator being depressed in fiber cushion pad body.Around extend at recess 67 in the region 69 of the fibrous material of compression.

Can use any technology of elastomer cushion pad body that can provide to form the fiber cushion pad body that carries out post processing.In order to illustrate, can as referring to figs. 1 through 8 descriptions to carrying out rear processing by connecting the fiber cushion pad body that a plurality of vertical one-tenth stratum reticulares form.Described rear processing can particularly advantageously be applied to fiber cushion pad body, and described fiber cushion pad body for not having the integrally molded body of sharp-pointed zone boundary between needs layer connected to one another.For this Unitarily molded three-dimensional fiber cushion pad body, the manufacture of the retaining element of reinventing and integrating of use ultrasonic energy can retain the structural intergrity of fiber cushion pad body.Even after post processing, fiber cushion pad body can present the transition region that density wherein and/or the value of fiber alignment in fiber cushion pad body vary continuously to another value.

Manufacture comprises that according to the method for the fiber cushion pad body of an embodiment using mould to form fiber cushion pad body by loose fibrous material goes forward side by side and exercise the processing of use ultrasonic vibration.With reference to Fig. 9, explain for formed the technology of fiber cushion pad body by loose fibrous material.The fiber cushion pad body forming thus can carry out described either side or the post processing of embodiment herein.

Fig. 9 manufactures according to the schematic diagram of the method for the fiber cushion pad body of an embodiment for explaining.Fiber cushion pad body forms independent main body by the fibrous material of heat cross-linking.At 81,82 and 83 places, illustrate each stage of described method.

Described method utilization is for the manufacture of the equipment 70 of fiber cushion pad body.Equipment 70 comprises mould, and described mould has the first mould 71 and the second mould 72.The first mould 71 and the second mould 72 can be respectively for example, by perforated material, formed by perforated sheet.The first mould 71 and the second mould 72 can have the three-dimensional internal shape corresponding with the shape of the interarea of fiber cushion pad body before post processing using ultrasonic energy.

Equipment 70 further comprises the gas guiding device 73 and 73 ' for the volume extracting gases from being limited by the first mould 71 and the second mould 72.Gas guiding device 73 can comprise controlled pilot set component 74.Controlled pilot set component 74 be configured so that can be in each zones of different of pilot set component 74 optionally by gas extraction in gas guiding device 73.Can control by pilot set component 74 position and the size in the region of volume 76 extracting gases from being limited by the first mould 71 and the second mould 72.Similarly, gas guiding device 73 ' can comprise controlled pilot set component 74 '.Controlled pilot set component 74 ' is configured so that in each zones of different of pilot set component 74 ', optionally gas extraction to be arrived in gas guiding device 73 '.Can by pilot set component 74 ' control volume 76 from being limited by the first mould 71 and the second mould 72 by gas extraction position and the size to the region in gas guiding device 73 '.

Equipment 70 also comprises the feedway 77 of supplying with fibrous material.Feedway 77 can comprise pipe, and described pipe can be supplied to fibrous material entrained in air-flow in mould 71,72.The mould being formed by the first mould 71 and the second mould 72 limit direction 78, the first moulds 71 and the second mould 72 spaced apart along described direction 78.Direction 78 is corresponding with the main load direction of the fiber cushion pad body that uses described method to form.

At 81 places, the first mould 71 and the second mould 72 are arranged at the first distance.By feedway 77, the loose fibrous material that comprises binding fiber and fiberfill fibers is supplied in mould 71,72.Loose fibrous material can be supplied with the form of fibre bundle.In air-flow 79 in being supplied to mould 71,72, carry fibrous material.In fibrous material being supplied to mould 71,72 when covering mold bottom, can be in the position of lower end that is conventionally arranged at mould 71,72 by gas extraction in gas guiding device 73 and 73 '.

The later phases illustrating at 82 places, fibrous material has been filled in mould and has been up to the standard 84.In this stage, still can fibrous material be supplied in mould 71,72 by feedway 77.Can in the air-flow of being supplied with by feedway 77, carry fibrous material.Can be at the fill level that is conventionally arranged on mould the position below 84 by gas extraction in gas guiding device 73 and 73 '.Along with fill level 84 raises, can use respectively controlled pilot set component 74 and 74 ' control from by mould 71 and 72 around the position of volume extracting gases.In order to illustrate, pilot set component 74 and 74 ' can comprise respectively a plurality of flap valves that are at least vertically spaced apart from each other, and flap valve can open and close in a controlled manner according to fill level 84.Use controlled pilot set component 74 and 74 ', can control the flow pattern 85 of air-flow.

Can control air-flow 85 so that passing the air-flow of mould has along the velocity component of direction 78, described direction 78 is corresponding with the main load direction of formed fiber cushion pad body.Can control air-flow, so that at least by the first mould 71 and the second mould 72 around the part of volume 76 in, air-flow 85 velocity component parallel with direction 78 is much larger than vertical with direction 78 and be parallel to the velocity component (i.e. the velocity component vertical with the drafting plane of Fig. 9) that interarea extends.

By controlling the flow pattern of air-flow, make it with the remarkable velocity component parallel with direction 78, pass and be deposited on the fibrous material in mould, fiber can be directed so that it has direction 78 as privileged direction in mould.

At 83 places, fibrous material has been filled in mould and has been up to the standard 84, and does not resupply fibrous material.The first mould 71 and the second mould 72 relative to each other move along direction 78, as 86 places illustrate.The first mould 71 and the second mould 72 can move with respect to laboratory reference frame.By the first mould 71 and the second mould 72 are relative to each other moved, the part with the density of enhancing can be formed at by the first mould 71 and the second mould 72 around volume 76 in.The first mould 71 and the second mould 72 are relative to each other moved and also can contribute in the region adjacent with the inner surface of the second mould 72 with the first mould 71, to establish the fiber alignment parallel with described inner surface, and/or contribute to establish the fiber alignment parallel with direction 78 in a part for the isolated volume 76 of inner surface with the first mould 71 and the second mould 72.

After the first mould and the second mould are mobile relative to each other, for establishing the pattern of the hope of the fiber alignment that is arranged in the fibrous material in mould or density, can be to fibrous material heat supply.By heat supply, can thermal activation binding fiber.Can form by the thermal activation of binding fiber the fiber matrix of heat cross-linking fiber.

Can supply with in every way the heat for the thermal activation of binding fiber.As 83 places in Fig. 9 illustrate, hot gas can be flowed to 86 and be supplied in mould.The mode that gas guiding device 73 and 73 ' can be used for determining is directed to hot gas the part that is arranged at the fibrous material in mould 71,72.Can be based on for example density of the fiber cushion pad body in region or the amount that thickness is controlled the hot gas that is supplied to the regional in mould 71,72 separately.

When fibrous material is inserted in mould, fibrous material can be preheating to the high temperature lower than the thermal activation energy of binding fiber.Thus, can reduce the amount of the needed energy of thermal activation binding fiber after the level that mold filling is reached to hope.

Can make at the fiber cushion pad body of mould 71,72 interior formation cooling.Can guide another air-flow, for example, there is the gas of room temperature or be cooled to be passed in lower than the gas of the temperature of room temperature the fiber cushion pad body of mould 71,72 interior formation.

In using Fig. 9, during illustrated method, a heating process is enough to produce three-dimensional fiber cushion pad body by loose fibrous material.This with wherein by a plurality of, vertically become network fiber sheet method stacking and that be bonded to each other to form contrast.Conventionally, need a plurality of heating stepses to manufacture the sheet of vertical one-tenth network fiber and make its combination to form cushion pad.

Can in described method, carry out other procedure of processing.In order to illustrate, be to form after three-dimensional fiber cushion pad body in mould 71,72, fiber cushion pad body can be inserted in auxiliary mould, to change the geometry of fiber cushion pad body, or further make its outer surface curing or level and smooth.Fiber cushion pad body can be inserted in auxiliary mould, it still locates at high temperature maybe can heat auxiliary mould simultaneously.

Can selectively form in the following way the part that density is greater than the density of elastic part: according to supply Position Control, be supplied to the density of the fibrous material in mould, selective compression is supplied to the fibrous material in mould, or processing afterwards.In order to illustrate, heating tool is used in fiber cushion pad body local its density that increases from mould 71,72 removes.Thus, a part for fiber cushion pad body can have high density, so that can partly locate seat cladding material to be anchored on fiber cushion pad body in high density.

Can be not only along a direction but be supplied to the fibrous material in mould along several directions compressions.As 83 places show, the first mould 71 and the second mould 72 can move in fibrous material, to produce the region with higher density relative to each other, and the region of described higher density is along the inner surface setting of the first mould 71 and the second mould 72.

Afterwards, can in the secondary side of fiber cushion pad body, compress and be inserted into the fibrous material in mould.For this reason, movably pusher can move along the direction vertical with direction 78, and described direction 78 is corresponding with the main load direction of fiber cushion pad body.

After both direction compressed fibrous material at least, can be to fibrous material heat supply to cause the thermal activation of binding fiber.

Described method also can be included in before fibrous material heat supply and be inserted into the fibrous material in mould along at least three orthogonal direction compressions.

From mould, removing fiber cushion pad body, using ultrasonic energy to carry out rear processing to it, as described in referring to figs. 1 through 8.

Although described the method according to each embodiment, can change in other embodiments.In order to illustrate, although described the rear processing of the fiber cushion pad body of molding, but can utilize any other technology, for example, by heat, merge the fiber cushion pad body that the vertical shape fibrage that has previously used Struto-or auxiliary net-forming technology to form forms pending rear processing.

In order to further illustrate, fiber cushion pad body needn't only consist of heat cross-linking fiber.In exemplary embodiment, when forming fiber cushion pad body, can optionally sticky material be supplied in mould, so that sticky material concentrates on the pre-position in the chamber being limited by mould.Can optionally supply with sticky material, with part, improve the combination density between fiber.

Although described the method for manufacturing fiber cushion pad body, after described fiber cushion pad body, use ultrasonic energy to process, wherein fiber is directed after in being inserted into mould, but forms the fiber along privileged direction orientation before can also be in fiber is inserted into mould.

Can be for the manufacture of the fiber cushion pad body that can be incorporated in diversified seat according to the method for embodiment.Wherein can use the exemplary seat of fiber cushion pad body to comprise the seat that automobile seat, train chair, aircraft chair, family are used and the seat of handling official business and using.Can also on the various assemblies of seat, use fiber cushion pad body.In order to illustrate, can receive the back part at the seat part of people's thigh, support people's back, headrest part maybe to need other assembly place of buffering to use fiber cushion pad body.

Claims

1. process fiber cushion pad body (1 for one kind; 30; 31; 51) method, described fiber cushion pad body (1; 30; 31; 51) by the fibrous material being cross-linked, formed, at least a portion of described fibrous material is heat-activatable, when applying load along main load direction (2), and described fiber cushion pad body (1; 30; 31; 51) be elastically deformable, described fiber cushion pad body (1; 30; 31; 51) before processed, there is the first shape (10),

Wherein move described fiber cushion pad body (1; 30; 31; 51) part (21), and to described fiber cushion pad body (1; 30; 31; 51) apply ultrasonic vibration, with by described fiber cushion pad body (1; 30; 31; 51) from described the first shape (10), reinvent into second shape (30) different from described the first shape (10).

2. method claimed in claim 1,

Mobile described part (21) wherein, with at described fiber cushion pad body (1; 30; 31; 51) in, form recess (23; 33 to 35; 53,54; 64; 65), and

Wherein to described fiber cushion pad body (1; 30; 31; 51) part applies described ultrasonic vibration, to cause the thermal activation of described heat-activatable fibrous material.

3. method claimed in claim 2,

Wherein when described fiber cushion pad body (1; 30; 31; 51), while having described the first shape (10), described part (21) has the first density, and

Wherein after applying described ultrasonic vibration, described fiber cushion pad body (1; 30; 31; 51) at described recess (23; 33 to 35; 53,54; 64; 65) face (25; 68) locate to have the second density, described the second density is greater than described the first density.

4. method claimed in claim 3, it further comprises

Flexible material (43) is attached to described recess (23; 33 to 35; 53,54; 64; 65) described (25; 68).

5. method claimed in claim 4,

Wherein said flexible material (43) is flexible weaving material.

6. claim 4 or method claimed in claim 5,

Wherein said flexible material (43) is heat-activatable, and

Wherein to described flexible material (43) and described fiber cushion pad body (31; 51) apply described ultrasonic vibration, with by the attached described flexible material of ultrasonic bonding (43).

7. the method described in any one in claim 3 to 6, it further comprises

By rigid element (27; 61) be attached to described recess (23; 53) described.

8. method claimed in claim 7,

Wherein make connector (29; 62) with described recess (23; 53) described (25) are directly adaptive, with by described rigid element (27; 61) be attached to described recess (23; 53) described (25).

9. the method described in any one in claim 2 to 8,

Wherein said recess (35; 54) form and have towards described fiber cushion pad body (31; 51) section that launch inside.

10. the method described in any one in claim 2 to 9,

Wherein said fiber cushion pad body (1; 30; 31; 51) fiber at least one region (9) is mainly along described main load direction (2) orientation.

11. methods claimed in claim 10,

Wherein said fiber cushion pad body (1; 30; 31; 51) there is the interarea (3 extending perpendicular to described main load direction (2); 32; 52),

Wherein through mobile described part (21), comprise described interarea (3; 32; 52) section, described interarea (3; 32; 52) described section moves to form described recess (23 along the direction parallel with described main load direction (2); 33 to 35; 53,54; 64; 65).

12. methods claimed in claim 10,

Wherein said fiber cushion pad body (1; 30; 31; 51) there is the inferior face extending in parallel with described main load direction (2),

Wherein through mobile described part, comprise the section of described face, the described section of described face moves to produce described recess along the direction perpendicular to described main load direction.

13. methods in any one of the preceding claims wherein,

Wherein pass through supersonic generator (20) to described fiber cushion pad body (1; 30; 31; 51) apply described ultrasonic vibration, simultaneously by the mobile described part (21) of described supersonic generator (20).

Method in 14. claims 1 to 12 described in any one,

Wherein moving after described part (21), to described fiber cushion pad body (1; 30; 31; 51) apply described ultrasonic vibration.

15. methods in any one of the preceding claims wherein,

Wherein said fiber cushion pad body (1; 30; 31; 51) be seat cushion.

Method described in 16. claims 15, it further comprises:

By described treated fiber cushion pad body (1; 30; 31; 51) be installed in seat.

Manufacture fiber cushion pad body (1 for 17. 1 kinds; 30; 31; 51) method, it comprises:

The loose fiber material that comprises at least two kinds of different types of fiber is supplied in three-dimensional mould (71,72), and described fiber comprises heat-activatable binding fiber,

To being filled into described fiber heat supply in described mould (71,72) with binding fiber described in thermal activation, form the fiber cushion pad body (1 of molding; 30; 31; 51), and

The fiber cushion pad body (1 of described molding is processed in use according to method in any one of the preceding claims wherein; 30; 31; 51).

Method described in 18. claims 17,

Wherein in air-flow (79,85), supply with described loose fibrous material, control the flow pattern of described air-flow (79,85) so that the described fiber in described mould (71,72) carries out orientation.